Method for cell construction



26, 1963 J. v. CARLISLE ETAL 3,111,744

METHOD FOR CELL CONSTRUCTION 3 Sheets-Sheet 1 Filed April 17, 1959 K \1& M

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F l G 3 F l G 2 Nov. 26, 1963 Filed April 17, 1959 J. V. CARLISLE ETAL METHOD FOR CELL CONSTRUCTION 3 Sheets-Sheet 2 4e 46 2 55 U 4 44 f 4 E Q 2 l I A i '1 6 I A 34 34 Y FIG 4 INVENTOR.

Nov 26., 1963 J. v. CARLISLE ETAL 3,111,744

METHOD FOR CELL CONSTRUCTION Filed April 17, 1959 5 Sheets-Sheet 3 IN V EN TOR.

FIG 6 United States Patent 3,111,744 METHOD FOR CELL CONSTRUCTION James V. Carlisle, Baton Rouge, La., and Theodore M- Arnold, Punta Gorda, Fla, assignors to Ethyl Corporation, New York, N.Y., a corporation of Virginia Filed Apr. 17, 1959, Ser. No. 807,244 2 Claims. (Cl. 29-1555) This invention relates to a new and novel method for the construction of electrolytic cells, and in particular to a method for the gaging and construction of a collectorcollector support frame sub-assembly for such cells.

This application is a continuation-in-part of prior patent application Serial No. 493,156, filed March 9, 1955, now Patent No. 2,912,750.

The manufacture of sodium and other alkali metals is carried out in electrolytic cells basically similar to the Downs cell described in US. Patent 1,501,756. Briefly, cells of this type include a housing containing a plurality of anodes each of which is surrounded by cylindrical portions of an individually mounted cathode. In the annular space between the anodes and the surrounding internal surfaces of the cylindrical cathode portions is positioned a foraminous metal diaphragm supported from above by a collector. The collector includes an outlet port for removal of the gaseous halogen and an annular inverted channel for manifolding and for removal of the alkali metal. This collector is supported by a frame which in turn is attached to and supported by the cell housing.

The concentricity and vertical disposition of the anodes with the surrounding diaphragms and cathode surfaces is an important attribute of a properly constructed cell. Attaining this objective has been a long standing problem in the industry. Inherent difficulties in the construction of these cells has been the lack of suitable methods for positioning the cathode with respect to the anodes, and for positioning the diaphragrns within the annular spaces between each anode and cathode cylindrical portion. Because of the fact that the cathode portions and the diaphragms surround substantially the entire length of each anode, it is quite difficult to position the diaphragm in between the cathode portions and the anodes within proper tolerances so as to provide the most eificient construction of the cell for operation. This can be particularly appreciated when it is noted that ordinarily the lateral distance between the anode and cathode is of the order of only 1 /2 inches and for best operation the diaphragm must be inserted equidistant from the anode and cathode over the entire length of the anode, which is about 3 to 4 feet or more in length. For proper construction of a cell it is essential that all of the assemblies and sub-assemblies be properly oriented one with respect to the other. Prior methods employed for achieving this result have not been adequate. Generally speaking, the life period of cells, that is the period between initial construction and when the cell must be broken down for rebuilding, has been erratic because of this faulty orientation of cell components. This has necessitated complete dismantling and rebuilding of the cell at all too frequent intervals. Such dismantling and reconstruction, in addition to being inherently expensive, also results in reducing production capacity of a plant. This arises from the fact a shop or plant has a certain number of stalls or cations for occupancy by as many cells; when a cell is being torn down and rebuilt, it is then not possible to merely insert a spare into that operating space. In present plant practice, because of short diaphragm life frequent partial dismantling of the cell is also quite common, largely because of the reasons already mentioned. The necessity of frequently diaphragm changes are especially acute when the collector-collector support frame is mis- 3,111,744 Patented Nov. 26, 1963 ice aligned. To change diaphragms the entire upper portion of the cell must be dissassembled. Obviously, also this is quite burdensome.

Until the present invention, the techniques in cell building left much to be desired, as above explained. Consequently, it is an object of the present invention to provide a method for the rapid and accurate construction of an electrolytic cell. A further object of this invention is to provide a method of constructing an electrolytic cell which will provide a cell having a longer life, higher efiiciency and increased productivity. A particular object of this invention is to provide a method for gaging collectors for cells having four anodes, and particularly for determining the symmetry of the collector ports according to a desired plan within desired tolerances. A further object is to provide a method for registering a gaged collector for assembly to a collector support frame in a predetermined spatial relationship. Another specific object is to provide a method for assembling the collector to the collector support frame in accurate alignment so that when inserted into the cell housing, proper positioning of a multiaperture cathode with respect to the anodes and the diaphragms is within prescribed tolerances.

The above and additional objects of this invention are provided by the method described herein. Broadly, the invention provides a method for the alignment and gaging of a collector of the kind used in fused salt electrolysis cells, said collector having four downwardly opening cylindrical ports terminating in a single plane and being centered on the corners of an approximate square. The steps of the process comprise engaging the walls of a diagonal pair of the ports, generally by outward thrust from within, and thereby positioning the collector by 10- cating these ports equidistant from a fixed point and in line therewith. This step positions the collector, and hence places the remaining diagonal pair of ports in a fixed relationship with regard to the said line. The symmetry of the collector-port plan is then gaged by comparing the disposition of a second line through the second pair of ports which bears a definite relationship to the first line when the second pair of collector ports are symmetrical with regard to said first line. Generally the second line is one extending through centers of the second or remaining pair of collector ports and its position is compared with the position of the said first line by means of an adjacent reference point which bears a fixed relation to the said second line and is indicative of the integral lateral and angular position of said line. This provides an integrated determination of the symmetry of the collector.

In addition, the invention further provides a method for positioning of a collector support frame and for the alignment and assembly therewith of a collector of the type above described. The method comprises vertically aligning the collector support frame and the collector on parallel planes, the collector support frame on the more elevated plane, and then laterally aligning the said frame with reference to adjacent indicia. The collector is next laterally oriented or positioned with regard to the collector support frame by engaging the walls of a diagonal pair of ports and positioning the said pair of ports equidistant from a point lying on a line between the ports. This step also positions the second pair of diagonal ports, and also the whole collector relative to the collector support frame. The proper alignment of the whole collector with reference to the collector support frame can also be determined by reference to adjacent indicia, said indicia being referenced with regard to the indicia upon which the collector support frame was referenced. Determination of the symmetry of the collector-port plan is performed as taught in the gaging step above. After gaging the collector ports then, all that remains to complete the collector-collector support frame sub-assembly is to fasten the two parts together.

The process of the invention will be more fully understood from the following detailed description of a preferred practical embodiment, reference being made to the accompanying drawings, in which FIGURE 1 is an isometric view of a suitable apparatus, or jig, for positioning the collector to the collector frame, and forming a cell sub-assembly, the figure having cutaway portions for the purpose of clarity and to show a portion of the collector and collector support frame in position, and

FIGURE 2 is a sectional elevation of one of a plurality of bosses, a pair of such bosses forming a locator which is a particular portion of the apparatus or jig, defined hereinafter, and

FIGURE 3 is a schematic plan view illustrating the action of the above mentioned locators of the jig in positioning, gaging and registering a collector for assembly into a collector-collector frame sub-assembly, and

FIGURE 4 is a partially sectioned elevation depicting the collector-collector support frame sub-assembly positioned in the jig, and

FIGURES 5 and 6 are isometric, partially sectioned and disengaged views of portions of the operative mechanism forming part of the jig.

The details of-construction and operation of the jig, for gaging a collector and establishing the sub-assembly of collector and collector support frame, are given in FIG- URES 14, inclusive. FIGURE 1 is an isometric partially sectioned view of the jig, a segment of a collector in operative relationship to the jig being shown. FIGURE 2 is an elevation showing a cross-section of a collector, and a collector support frame in operative relation to elements of the jig, and FIGURES 3 and 4 are sectional detail illustrations of certain elements of the jig.

Referring to FIGURE 1, the jig includes a base 11 and a superstructure including a plurality, generally four, of upright columns 12 which rigidly support a horizontally disposed frame 13. Attached to and forming part of the jig base 11 is a collector aligning mechanism 21. The aligning mechanism 21 includes mechanism hereafter described. A bearing plate 23, corresponding generally in outline to the outline of the bottom of a collector is centrally and rigidly attached to the upper surface of the housing 22. The surface of the bearing plate 23 is in a plane paralleling the plane of the upper surface of the superstructure frame 13, and more specifically, the plane defined by registration plates 15 attached to members of the superstructure frame 13.

Projecting through openings in the bearing plate 23 are two sets, of two each, of locators, these locators 24 24 34 34 each being a pair of lugs or bosses as later described. Each set of locators thus consists of two pairs of two bosses each, and therefore each locator defines a rectangle in a horizontal plane. The two locators of each recangle are capable of limited movement hereafter more explicitly defined. Generally, however, one set of locators (bosses 24 24 are adapted to engage the outward walls of one diagonal pair of cylindrical ports or openings of a collector. This is termed the unidirectional set. The other set of locators (bosses 34 34 termed the bidirectional set, are adapted to engage by generally outward movement, the outward walls of a second diagonal pair of collector ports.

Mechanism hereafter described is provided for movement of the pairs of bosses in each set toward or from the center of the bearing plate 23. An operating wheel 25 provides for actuating the mechanism for providing movement of the locator bosses 24 24 of the unidirectional set. Movement of one pair is accompanied by an equal and corresponding movement of the other pair of the set. In other words, movement of the bosses 24 of one pair toward the center of the bearing plate is accompanied by an equal movement of the bosses 24 of the opposite pair toward the center. Thus, it is seen that the bosses 24 2.4 of the unidirectional set always define a rectangle having a fixed center, a constant width and a variable length.

With respect to the bosses 34 34 of the bidirectional set, an operating wheel 35 provides for actuating mechanism providing movement of the pairs of bosses 34 34 to or from each other as the case may be. It is seen that the bosses 34 34 of the bidirectional set always are always are located on the corners of a rectangle having a constant width. However, the long dimensions of the rectangle so-defined can be at a variable angle to the long dimension of the rectangle defined by the bosses 24 24 of the unidirectional set. Further, the center of the didirectional bosses 34 34 rectangle is movable, and may or may not coincide with the center of the rectangle of the unidirectional boss rectangle.

The disposition of the rectangle defined by the centers of the bidirectional bosses 34 34 is visually indicated, and made available for a size and alignment check by an extension 33 projecting through the side of the housing 22. The extension 33 has a machined hole for loosely receiving a tolerance pin 31. A bracket 32 mounted generally below the extension and rigidly to the side of the housing 22, also has a machined hole therein for snugly receiving the pin 31. Accordingly, passage of the tolerance pin through the opening in the extension 33, and reception in the hole in the bracket 32 means that the general disposition of the bidirectional bosses 34 34 with respect to the unidirectional bosses 24 24 is constant within a certain tolerance range. The center line of the pin 31 in position in the receptacle provided in the angle 32 is, in effect, a fixed reference point to which the other portions of the jig, and the parts of the sub-assembly established with the figure, bear an explicit relation.

The functioning of the two sets of bosses is further illustrated by FIGURE 3 which is a schematic plan view showing the position of the sets of bosses 24 24 34 34 in operative contact with the wall surfaces of the circular ports of a collector. It will be seen that each of the two sets of bosses are adapted to engage by outward movement the walls of a diagonal pair of the ports of a collector.

The superstructure of the jig includes a frame 13 having special corner members 14 on which are permanently mounted registration plates 15. An indexing mark 16 is scribed on each of the registration plates 15. The operative relation of a collector support frame 51 to the jig frame 13 and registration plates 15 is shown in part by FIGURE 4 and in part by FIGURE 1. Referring to FIGURE 4, a collector casting 41 is shown in partial section, resting on the bearing plate 23 of the jig. The collector casting includes four ports, the walls 42 4-2 of two of the ports being shown. The ports open into a central dome 43 which terminates in a flanged opening 44 for connection, in an operating cell to a chlorine duct. The dome 43 is permanently attached to a ring member 45, which is attached to four vertical support members 46, having a threaded portion at the upper end thereof.

The collector support frame 51 includes two long channel members 52 and two cross members 53, the cross members being suitably angle irons set in slightly from the ends of the channel members. The support members from the ring member are attached to the collector support frame by bolting to supplemental cross members 54. When a collector-collector support frame is properly assembled within the jig, a constant clearance is measurable between the underside of the ends of the channel members 52 and the registration plates 15. Further orientation of the collector support is provided by registration marks 55 in the frame cross members 53, and similar marks 56 in the webs of the channel members 52. These latter are aligned with registration marks 17 on pillow blocks 18 mounted on the jig frame and defining a line at right angles with a line between the registration marks 16 on the opposite corners of the jig.

In using the jig to establish a sub-assembly of a collector and collector frame, the operator first provides, through hand-wheel 25 inward movement of the bosses of the unidirectional set to their stopping point. Next, with pin removed, bosses 34 34 of the bidirectional set are moved inwardly to their stopping point by operation of hand wheel 35. The collector, with the collector support frame loosely attached thereto by the support bolts,

is then lowered on to the bearing plate 23. The operator then moves the bosses 24 24 of the unidirectional set outwardly to make contact with the inner surface of two of the collector outlet ports. This operation locates these two collector port walls generally equidistant from the center of the jig (the boss pairs of this set being movable only equidistant from the jig center) and also thus positions generally the collector on a line coinciding generally with a line equidistant between the bosses of each pair of the set. that first the collector is adjusted and positioned by the action of the unidirectional locator 24 24 or sets of bosses. Outward movement of the boss pairs in this set provides lateral shifting of the collector until tangential contact is made by the collector port walls with each of the four bosses 24 24 Then the operator, by rotating hand-wheel 35, causes outward movement of the bidirectional bosses 34 34 this movement being continued until further movement is prevented by contact of at least three of the bosses against the collector port walls. Re ferring to FIGURE 3, it will be seen that if the collector ports define perfect circles, and these circles are centered on the corner of a perfect square, then all four bosses 34 34 of the bidirectional set will engage the collector port walls. In addition, the long dimension of the rectangle formed by the bidirectional bosses will be precisely at right angles to the long dimension of the rectangle defined by the unidirectional bosses 24 24 On the other hand, if the above mentioned desired relationships of the collector ports do not exist owing to warpage of the collector, when any of the bidirectional bosses 34 34 make contact with a collector port wall, further outward movement will be normally accompanied by rolling movement along the wall and radial shifting, and possibly lateral shifting, of the rectangle defined by the bidirectional bosses. By lateral shifting is meant that the long axis of the rectangle defined by the bidirectional bosses 34 34 is shifted to a different bisecting point with respect to the recangle defined by the unidirectional bosses 24 24 This lateral shifting may also be accompanied by a change in the angle of intersection of the long axes of the rectangles. This shifting is, of course, reflected in the position of the extension 33.

It is seen that the position of the extension 33 provides, by reference to the bracket 32, an integrated indication of the position of the rectangle defined by the bidirectional set of bosses relative to the rectangle defined by the unidirectional set. This indication integrates lateral, lineal and angular position of the two said rectangles in the horizontal plane. A rapid tolerance determination based on this integrated indication is possible with the pin 31. The pin is inserted through the hole in the extension 33, and if it is possible to insert the pin 31 further into the receptacle in the bracket 32, it is established that the collector is properly aligned and meets the required port location specifications. If the pin is thus received in the receptacle in the bracket 32, the collector frame is rigidly secured to the collector with the reference marks 16, 55, 17, 56 already mentioned being properly registered.

FIGURE 6 is an enlarged, partially sectioned view of one pair of bosses 24 of the unidirectional bosses and operating mechanism therefore, forming a portion of the jig. Referring to FIGURE 6, the pair of bosses 24 are Thus, referring to FIGURE 3, it is seen plate slidably mounted on a movable plate 26 The movable 26 is supported by slides, not shown, attached within the housing 22. Rotation of the hand-wheel 25 causes rotation of a threaded shaft 27 by actuating a stub shaft 28 and a bevel gearset 29. Movement of the threaded shaft 27 along its axis is prevented by a double thrust bearing, not shown, engaging the shoulder of an enlarged section 30 of the threaded shaft 27. The other pair of bosses 24 not shown, also operatively engage a threaded section of the shaft 27, the thread lead being opposite in direction but of equal pitch to the threaded portion actuating movement of the opposite boss 24 pair. Thus rotation of the hand-wheel 25 causes equal movement of the boss pairs 24 24 in opposite directions.

The mechanism for actuation of the bidirectional bosses 34 34 is illustrated by FIGURE 5, this figure being an isomertic sectional view of a portion of the collector aligning mechanism 21. Referring to FIGURE 5, one pair 34 of the bidirectional bosses is shown. The bosses 34 are attached to a slidable plate 36 supported adjacent to a support plate 37 by slides not shown attached to the support plate 37. Movement of the slidable plate 36 is provided by rotation of a threaded shaft 38 which extends through the wall of the housing 22 and is fastened to the operating wheel 35. The support plate 37 supports also a second slidable plate not shown which in turn conveys a second pair of bidirectional bosses 34 The support plate 37 is mounted within the housing by bearing support means not shown which permits limited rotational movement, and lateral and lineal movement, all in a horizontal plane. From the foregoing it is seen that outward movement of the boss 34 34 pairs can be accompanied by a shift in the disposition of the rectangle defined by the bosses with respect to its angle to the unidirectional boss rectangle and also with respect to the position of its center relative to the invariant center of the rectangle defined by the unidirectional bosses.

From the foregoing, it will be seen that, in operation, the bosses 24 24 34 34 will normally go through limited movement along the walls of the collector ports. This movement may be by sliding contact, but it has been found that rolling contact is particularly effective and desirable. A preferred design for the bosses is illustrated in FIGURE 2, this figure being a sectional elevation of an embodiment of a boss providing frictionless rolling contact. Referring to FIGURE 2, the boss assembly includes a pedestal 62 which is mounted upon the slidable plate 26 and attached thereto by cap screw 63. A collar 64 is positioned by the shank of the pedestal 62. The top of the pedestal 62 has preferably a rolled crown as shown. A roller 65 is positioned by the pedestal and supported by the collar 64, the lowermost surface 66 of the roller is positioned slightly above the top level of the bearing plate 23. The wall 42 of the collector port engages the periphery of the roller 65. A chamfer 67 on the upper portion of the roller 65 is an extension of the outline of the crown of the pedestal 62. This continuity of outline is beneficial in several respects. In lowering the collector casting in place, this inclusion facilitates placement. In addition the disposition of the extremities of the pedestal crown from the roller periphery assures that rolling contact is maintained in aligning the collector despite the occasional presence of minor surface protrusions.

Upon completion of the collector-collector frame subassembly as above described, it is available for addition of the diaphragms to complete the upper portion of a cell assembly.

In a careful comparison of the performance of a group of cells constructed with the apparatus of our invention with performance of a group constructed according to previous methods it was found that the former group provided an increase of approximately 1.5 percent in current efficiency. In addition, it was found that the average effective life of the former group of cells was a significant improvement over the preceding practice, particularly with respect to the diaphragm life. Since the cost of construction of cells with the present apparatus is substantially the same as by the former practices, it is apparent that our apparatus is highly beneficial and economical.

Having described the apparatus of our invention in some detail and the manner of its use, what we claim is:

1. A method for gaging a fused salt electrolysis cell collector of the type having four downwardly opening cylindrical ports terminating on a single plane and being centered on the corners of an approximate square, comprising engaging the outer walls of a diagonal pair of said ports by outward thrust from within and positioning said ports equidistant from a point lying on a fixed line and passing through the center of the said pair of ports, measuring the relative position of a line extending through the center of the second diagonal pair of ports and through the fixed point and comparing the disposition of the line through the second pair of ports relative to the first line by measurement of the displacement of the second line from an adjacent indicia this displacement being indicative of the proper intergrated lateral and angular positioning of the collector.

2. A method for the gaging of a collector and for the aligning and positioning of a collector and support frame for assembly with the collector to form a sub-assembly for a fused salt electrolysis cell, said collector having four cylindrical ports opening in the collector face thereof terminating on a single plane and being centered on the corner of an approximate square, comprising the steps of vertically aligning a collector support frame and collector on parallel planes, the collector support frame being on the more elevated plane, engaging the interior walls of a diagonal pair of cylindrical ports of said collector by outward thrust from within, positioning the collector until the said ports are located equidistant from a fixed point lying on a line passing through the centers of said two ports, then laterally gaging the position of the collector support frame relative to adjacent indicia by measuring the relative position of a centerline extending through the centers of said second pair of diagonally opposite collector ports with respect to said fixed point, the displacement of the said second line from the adjacent indicia being indicative of the proper integrated lateral and angular positioning of said collector, and thereafter fastening the collector and collector support frame into a subassembly.

References Cited in the file of this patent UNITED STATES PATENTS 1,501,756 Downs July 15, 1924 1,826,503 Buckwalter Oct. 6, 1931 2,427,685 M'idtlyng et al Sept. 23, 1947 2,664,843 Turner Jan. 5, 1954 2,770,592 Fentress Nov. 13, 1956 2,912,750 Carlisle et a1. Nov. 17, 1959 

1. A METHOD FOR GAGING A FUSED SALT ELECTROLYSIS CELL COLLECTOR OF THE TYPE HAVING FOUR DOWNWARDLY OPENING CYLINDRICAL PORTS TERMINATING ON A SINGLE PLANE AND BEING CENTERED ON THE CORNERS OF AN APPROXIMATE SQUARE, COMPRISING ENGAGING THE OUTER WALLS OF A DIAGONAL PAIR OF SAID PORTS BY OUTWARD THRUST FROM WITHIN AND POSITIONING SAID
 2. A METHOD FOR THE GAGING OF A COLLECTOR AND FOR THE ALIGNING AND POSITIONING OF A COLLECTOR AND SUPPORT FRAME FOR ASSEMBLY WITH THE COLLECTOR TO FORM A SUB-ASSEMBLY FOR A FUSED SALT ELECTROLYSIS CELL, SAID COLLECTOR HAVING FOUR CYLINDRICAL PORTS OPENING IN THE COLLECTOR FACE THEREOF TERMINATING ON A SINGLE PLANE AND BEING CENTERED ON THE CORNER OF AN APPROXIMATE SQUARE, COMPRISING THE STEPS OF VERTICALLY ALIGNING A COLLECTOR SUPPORT FRAME AND COLLECTOR ON PARALLEL PLANES, THE COLLECTOR SUPPORT FRAME BEING ON THE MORE ELEVATED PLANE, ENGAGING THE INTERIOR WALLS OF A DIAGONAL PAIR OF CYLINDRICAL PORTS OF SAID COLLECTOR BY OUTWARD THRUST FROM WITHIN, POSITIONING THE COLLECTOR UNTIL THE SAID PORTS ARE LOCATED EQUIDISTANT FROM A FIXED POINT LYING ON A LINE PASSING THROUGH THE CENTERS OF SAID TWO PORTS, THEN LATERALLY GAGING THE POSITION OF THE COLLECTOR SUPPORT FRAME RELATIVE TO ADJACENT INDICA BY MEASURING THE RELATIVE POSITION OF A CENTERLINE EXTENDING THROUGH THE CENTERS OF SAID SECOND PAIR OF DIAGONALLY OPPOSITE COLLECTOR PORTS WITH RESPECT TO SAID FIXED POINT, THE DISPLACEMENT OF THE SAID SECOND LINE FROM THE ADJACENT INDICIA BEING INDICATIVE OF THE PROPER INTEGRATED LATERAL AND ANGULAR POSITIONING OF SAID COLLECTOR, AND THEREAFTER FASTENING THE COLLECTOR AND COLLECTOR SUPPORT FRAME INTO A SUBASSEMBLY. 